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Valid for serial no. 0645--xxx--xxxx0740 801 020 070316
Miggytrac 3000
104
Service manual
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Rights reserved to alter specifications without notice.
ENGLISH 2....................................................
ENGLISH
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TOCe
1SAFETY 2...........................................................
2 ELECTRICAL BLOCK DIAGRAM 4....................................
2.1 Component description 4.....................................................
2.2 Wire diagram from ser.nr. 0649xxxx 5..........................................
2.3 Wire diagram before ser.no 0649xxxx 6........................................
3FILTER 7............................................................
3.1 General 7..................................................................
4 CONTROL UNIT _ CARRIAGE “D” 8...................................
4.1 General 8..................................................................
4.2 Component location on main board MMC231 8..................................
4.3 Component location, supply board LPW_123 9..................................
4.4 D1.1 Rectifier , V oltage supply 9...............................................
4.5 D1.2 + 5 V 10...............................................................
4.6 D3 Motor driver 11...........................................................
4.7 D4 Start /stop Wire Feeder 12.................................................
4.8 D5 Start / Stop switch 13.....................................................
5 CONTROL UNIT “C”-- WIRE FEEDER 14...............................
5.1 General 14..................................................................
5.2 Power 14....................................................................
5.3 C1.1 + 5 V 14...............................................................
5.4 C1.2 + 24 V 14..............................................................
5.5 C2 Output gas valve 15.......................................................
5.6 C3 Motor driver 15...........................................................
5.7 C4 Start / stop welding 16.....................................................
5.8 C5 Start / stop wire feeder 16.................................................
6 TROUBLESHOOTING 17..............................................
6.1 Carriage not working 17.......................................................
6.2 Wire feeder not working. 18....................................................
6.3 Cannot start welding 19.......................................................
6.4 Speed calibration for travel unit 20..............................................
6.5 T ravel unit motor cut--out 22...................................................
6.6 Preheat time 24..............................................................
7 MAINTANANCE 26....................................................
7.1 Daily 26.....................................................................
8 ORDERING OF SPARE PARTS 26......................................
SPARE PARTS LIST 27...................................................
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1SAFETY
Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of welding equipment. The following recommen-
dations should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well--acquainted with the operation of the welding
equipment. Incorrect operation of the equipment may lead to hazardous situations which can result
in injury to the operator and damage to the equipment.
1. Anyone who uses the welding equipment must be familiar with:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding
2. The operator must ensure that:
S no unauthorised person is stationed within the working area of the equipment when it is
started up.
S no--one is unprotected when the arc is struck
3. The workplace must:
S be suitable for the purpose
S be free from draughts
4. Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame--proof
clothing, safety gloves.
S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during operation.
GB
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WARNING
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERAT ING.
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-
TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK -- Can kill
S Install and earth the welding unit in accordance with applicable standards.
S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S Insulate yourself from earth and the workpiece.
S Ensure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
S Keep your head out of the fumes.
S Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS -- Can injure eyes and burn skin.
S Protect y our eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
S Protect bystanders with suitable screens or curtains.
FIRE HAZARD
S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
S Protect y our ears. Use earmuffs or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
WARNING
This product is intended for industrial use. In a domestic environment this
product may cause radio interference. It is the user’s responsibility to take
adequate precautions.
GB
2 ELECTRICAL BLOCK DIAGRAM
2.1 Component description
No. Description Type
A Filter, voltage supply LC filter in metal casing
B Filter, m otor wire feeder LC filter in metal casing
C Control unit, wire feeder MMC231 and LPW123
D Control unit, travel unit MMC231 and LPW123
D1+D2 Diode 1N4002
E Gas valve 24 V DC
F Relay, start welding 24 V DC, 5A
M1 Motor carriage 24 V DC
M2 Motor wire feeder 24 V DC
R1 Potentiometer, remote Volt 1k, 1 W
SW01 Start/Stopswitch Telemecanique
XP01 Connector plug 23-- pin Burndy, male
XP02 Chassisplug wire feeder 2-- pin Amphenol, male
XS02 Connector wire feeder 2-- pin Amphenol, female
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2.2 Wire diagram from ser.nr. 0649xxxx
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2.3 Wire diagram before ser.no 0649xxxx
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3FILTER
3.1 General
Sections A to F refer to wiring diagram 3.3
Each unit has its own letter code which is divided into section numbers.
A Filter, Voltage supply
For filtration of the 42 V AC a standard LC--filter in a metal casing is used. The filter
is bolted inside to the rear wall of the tower, close to the cable bushing. The screen of
this cable is connected to the same bolt.
Filters of different makes were used – PE and Corcom – both designed for 1 A/250 V.
OutIn
B Filter, motor wire feeder
From serial no. 0644 a second filter (like “A”) is bolted inside the tower. That’s for
filtration of electrical noise from the wire feeder motor. It‘s the upper filter in the tower.
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4 CONTROL UNIT _ CARRIAGE “D”
4.1 General
The controller consists of 2 circuit boards, the main board MMC231 and the voltage
supply board LPW123. The circuit boards are mounted in separate aluminium frames
which are bolted together.
These are insulated from each other by plastic washers. It is important to prevent
electric current passing through the chassis to the switch regulator for the voltage
supply board, which is bolted to the aluminium frame.
The main board is bolted through 6 spacers and shimmed with 3 mm diameter plastic
washers to give the correct spacing between the switch and the front panel. The 2
central nuts are also insulated using the same type of plastic washers.
LPW123
MMC231
The main board consists of a m icroprocessor ( μP), a drive unit for the display, a
display switch and a drive unit for the motor. The microprocessor is an OTP version
and therefore cannot be reprogrammed. When upgrading to a new software the
complete microprocessor must be replaced.
!
When replacing the microprocessor use the correct to o ls and
wear a p ersonal earth device.
4.2 Component location on main board MMC231
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4.3 Component location, supply board LPW_123
11
12
13
15
16
16
10
10
4.4 D1.1 Rectifier, Voltage supply
The inputs are protected by a 1.6 A “fast” fuse. A 10 ohm NTC r esistor ( R0) limits the
current when the voltage is switched on.
R1 is a varistor that protects the board against a high input voltage. T he varistor
short-- circuits at voltages above 50 V AC, the current through the fuse rises sharply
and the fuse blows. Occasionally the varistor may short circuit, with the result that the
fuse blows as soon as you connect the supply voltage again. T he varistor is easily
replaced by cutting the legs close to the casing, then unsoldering the legs
individually.
The input filter consists of C1, C13, L1 and L2 plus C2 and C12.
The diode bridge, D1 and D7, rectifies the input voltage, which is around 60 VDC at
42 V AC. The voltage from D1 is fed to terminal 13 on terminal block “K1” and to the
motor transistors on the MMC_231 board. D7 supplies the 5 V and 24 V regulators.
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4.5 D1.2 + 5 V
+5V+60V
K2_3
K1_15
The 5 V voltage supply is based on a switch regulator, dimensioned for a max.
current of 1 A .
The base voltage (+ 60 V at 42 V AC) from rectifier D7 and capacitor C3 supplies the
regulator with voltage .
The regulator switch outputs a voltage with a frequency o f 100 KHz which is
smoothed by choke coil L3 and capacitor C10.
D6 is a schottky--diode which protects the regulator’s output .
The regulator has a feedback input which monitors the output voltage, via a voltage
divider R12+R13/R11.
Output voltage should be min. 4.9 V and max. 5.1 V .
The regulator is bolted on the aluminium frame and insulated from the frame with
plastic washers.
LPW123
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4.6 D3 Motor driver
Drive The motor is driven by the base voltage from the voltage supply board
(around 60 V DC at 42 V AC supply) and is controlled by 4 MOS--FET
transistors that are connected to an H rectifier bridge.
Speed The microprocessor generates a modulated pulse width signal. This pulse
width corresponds to the programmed speed, port A4 connection 30. This
pulse--modulated voltage is then smoothed to DC by a RC filter (R17 and
C5), and is fed to a OP amplifier that is wired as a “voltage follower”, i.e. a
circuit that is used to keep the voltage at these two inputs constant. The
second input is a filtered voltage from the motor output. This feedback signal
is split by a voltage divider (R9/R10 across R14) and smoothed by C3. The
zener diode D20 (4.3 V) protects the input against too high a voltage.
The output from the OP amplifier (a pulse width signal that also varies in
frequency) controls the opts witches D16_1 and D17_1. These then pulse the
MOS--FET transistors T6 and T7
Direction The direction of rotation of the motor is determined by which of the
“diagonals” in the H rectifier bridge is conducting – either T7 and T8 or T6
and T9. Ports A5 (connection 29) and A6 (connection 28) are controlled by
the microprocessor.
Braking The motor is braked when transistors T6 and T7 short--circuit the motor . This
is also controlled by a pulse width that is varied to ensure smooth braking of
the motor.
Protection To protect the motor from overload the microprocessor monitors the motor
current. This is read as the voltage drop across shunt R15 (0.47 ohm) and is
filtered by a RC filter (R16 and C4). Zener diode D21 (4.3 V) protects the
input against voltage overload.
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4.7 D4 Start /stop Wire Feeder
Control unit Carriage (”D”) Control unit Wire Feeder (”C”)
D26
R29 ”5”
”4”
μ
P-- Port D2
+60V
(pin 22)
R28
”9”
”7”
+5V
D24
C8
R23
μP-- Port E5
RN1
(pin7)
(pin 46)
T13
”D4”
”C5”
The upper control unit ( Travel unit) provides the start/stop function for the wire feeder
by means of a relay that is connected between terminals 4 and 5 on the terminal
block.
The relay is mounted in a socket midway along the length of the main board.
Port D2 (connection 22) from the microprocessor goes high (+5 V) and opens T13
via resistor R28. The resistor has been selected to limit the current through T13 so
that the voltage drop across the r elay coil is 15 -- 20 V.
The relay output can carry up to 0.5 A. To limit the current on the relay contact, a
500mA PTC (R29) is connected in series with the signal.
The relay is secured to the socket with a piece of foam placed between the top of the
relay and the power unit.
1
2
3
4
5
6
7
8
9
A
Relay
Make.: Günther
Model: 3570 1210 151 or 3570 1210 241
Art. no.:0398 146 910
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4.8 D5 Start / Stop switch
Miggytrac 3000 has a start/stop switch on the top of the tower. The start is green, the
stop is red. Both switches are NO and are connected between terminals 6, 7 and 9 of
the upper control unit (D).
Terminal “9” is +5 V to both switches. Terminal “7” is start input and terminal “6” is
stop.
Control unit Carriage (”D”)
START SW1_A
D24 C8
R23 ”7”
”9”
SW1_B
”6”
STOP
μ
P--Port E5
D23 C7
R22
+5V
RN1
(pin7)
RN1
(pin3)
(pin 46)
μ
P--Port E3
(pin 49)
The inputs have a filter that protects them from voltage overload (Zener diode at
4.3 V) and a RC filter which filter out any ripple from the switch. RN1 is i pull down
R--Net for port E on the microprocessor.
The normal values are 1 k ohm for R22 + R23 and 100 nF for C7 + C8.
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5 CONTROL UNIT “C”-- WIRE FEEDER
5.1 General
The wire feeder unit is based on the same circuit board as that used for the carriage
control unit. T he control units differ only in a few components and the microprocessor
software that runs them.
The circuit board for voltage supply has a 24 V output (terminal 16) that supplies the
gas valve and the start relay.
For a more detailed description, see on page 10.
5.2 Power
See on page 11 for explanation.
5.3 C1.1 + 5 V
See on page 12 for explanation.
5.4 C1.2 + 24 V
+ 24V+ 60V
K1_16
K1_16
K2_2
The 24 V voltage supply is based on a LM317 series regulator (IC1), dimensioned for
a max. current of 0.5 A.
The base voltage (+ 60 V at 42 V AC) from rectifier D7 and capacitor C3 supplies the
regulator with voltage.
The regulator has a feedback input (pin.1) which monitors the output voltage, via
voltage divider R8/R9. R7 is not mounted. D5 is an over voltage protection for the
reg. output pin.
Output voltage should be min. 22 V and max. 26 V.
The regulator is bolted on the aluminium frame and insulated with plastic washers.
LPW123
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5.5 C2 Output gas valve
The lower control unit (wire feeder unit) provides the on/off function for the gas valve
by means of an “open collector” (0 V) output (T12) that is connected to terminals 3 on
the terminal block. T he gas valve is a 24 V DC solenoid and the +24 V is connected
to terminal “16” on the supply board.
This output is controlled by the uP and from the frontpanel it’s possible to program
the time for “pre flow” and “post flow” (the time the gas valve opens before welding
start and close after welding stop).
Port D3 (pin 23) from the microprocessor goes high (+5 V) and opens T 12 via
resistor R27. The T12 (BC337) is a NPN--transistor 50 V -- 0,8 A.
”16”
”3”
μ
P-- Port D3
(pin 23)
R27
T12
REG.
+24V
Power
E
C2
5.6 C3 Motor driver
See on page 13 for explanation.
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5.7 C4 Start / stop welding
”16”
REG.
+24V
D26
R29 ”5”
”4”
μP--Port D2
+60V
(pin 22)
R28
T13
”10”
”F”
”B”
XP01
C4
F
Power
5.8 C5 Start / stop wire feeder
See on page 14 for explanation.
Not working
Check voltage supply (36--46 V
AC) between pins A and B on
conect. XS01.
Check if the pushbuttons on
frontpanel are working.
Check start/stop switch and
the voltage on term. ”6” and
”7” (see on page 15).
OK
OK
YESNO
Are front panels lit
up?
Check the fuse (1,6A).
Check the voltage (5 V DC)
between term. ”10” and ”15”.
Check the cable (with 4--pin
connector) between supply
board and main board.
Check wire connection on
term. ”1” and ”2”.
Check voltage (6--36 V DC)
between term. ”1” and ”2”
when start
Check motor.
Replace the
motor.
Check connector
XP01 and filter
”A”
Replace fuse
Fuse burns out
again.
Replace the
electronic unit.
Same voltage should be
present between term. 11 and
12 on the supply boards.
OK
OK
NEG
OK
OK
OK
OK YESOK
NEG
NEG
OK
NO
NO
NO
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6 TROUBLESHOOTING
6.1 Carriage not working
Not working
Check voltage supply (36--46 V
AC) between pins A and B on
conect. XS01.
Check startsignal from the
upper electronic
(see on page 14).
OK
OK
YESNO
Are front panels lit
up?
Check the fuse (1,6 A).
Check the voltage (5 V DC)
between term. ”10” and ”15”.
Check the cable (with 4--pin
connector) between supply
board and main board.
Check wire connection on
term. ”1” and ”2”.
Check filter B and wire
connection on chassis plug
XP02
Check voltage (6--36 V DC)
between term. ”1” and ”2”
when start
Check motor.
Replace the
motor.
Check connector
XP01 and filter
”A”
Replace fuse
Fuse burns out
again.
Replace the
electronic unit.
Same voltage should be
present between term. 11 and
12 on the supply boards.
OK
OK
NEG
OK
OK
OK
OK YESOK
NEG
NEG
OK
NO
NO
NO
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6.2 Wire feeder not working.
/